Raped vacuum casting performance evaluation of product with matting components for beta prototyping
Also available in printed version
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| Format: | Master's thesis |
| Language: | English |
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Universiti Teknologi Malaysia
2025
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| Online Access: | https://utmik.utm.my/handle/123456789/44432 |
| Abstract | Abstract here |
| _version_ | 1854934097200152576 |
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| author | Nur Nabilah Mohammad Mustafa |
| author2 | Mazlan Abdul Wahid, supervisor |
| author_facet | Mazlan Abdul Wahid, supervisor Nur Nabilah Mohammad Mustafa |
| author_sort | Nur Nabilah Mohammad Mustafa |
| description | Also available in printed version |
| format | Master's thesis |
| id | utm-123456789-44432 |
| institution | Universiti Teknologi Malaysia |
| language | English |
| publishDate | 2025 |
| publisher | Universiti Teknologi Malaysia |
| record_format | dspace |
| record_pdf | Abstract |
| spelling | utm-123456789-444322025-08-20T21:11:58Z Raped vacuum casting performance evaluation of product with matting components for beta prototyping Nur Nabilah Mohammad Mustafa Mazlan Abdul Wahid, supervisor Mechanical engineering Also available in printed version Integration of Additive Manufacturing (AM) and Vacuum Casting (VC), or commonly termed as Rapid Vacuum Casting (RVC), has a strong potential to expedite product development process mainly for beta prototyping. Properties such as dimensional accuracy, tolerance, shrinkage and air entrapment were previously studied focusing on pattern making, mold making and optimization of VC process. However, lack of studies to analyse these properties to cater for products with mating components. Thus, the objectives of this study were to evaluate the performance of RVC parts as replacement mating components based on AM patterns in terms of dimensional accuracy and surface roughness. The processing parameters of vacuum casting process were optimized and the capability of the mating components was analysed to comply with test performance according to IEC 60601-1 standard. In Phase 1, detailed designed of the specimens were modelled followed by pattern fabrication using Fused Deposition Modelling (FDM) method. The VC process was then conducted using Taguchi method to obtain optimized parameter settings. The results were analysed using analysis of variance and confirmation experiment was performed. Subsequently, stereolithography (SLA) pattern and Multi Jet Fusion (MJF) pattern were utilised in VC using the predicted optimized parameters. Next, functional performance analysis of the three patterns (FDM, SLA and MJF) was conducted. In evaluating the mating capability, two assembly components of a handheld enclosure were selected as a case study. In Phase 2, the pattern was redesigned to minimize defects and the mold was fabricated. Next, functional performance analysis followed by a drop test and mold relief stress test were conducted. In general, the overall results showed a variation of deviation in x-axis and y-axis of the components. The maximum deviations of the casting part before optimization for Dimensions A and B were 0.106 mm and 0.246 mm, respectively. After optimization, the deviation decreases by about 64.2% and 80.1% for Dimension A and Dimension B, respectively. The variation was due to the direction of filling material in the silicone. The surface finish of the casting parts differs slightly from the AM patterns. The surface roughness decreases about 1.8% to 9.6 % from master pattern. During VC, the silicone mold was able to produce about 22 single components before it was degraded. The maximum warpage value of top part specimen in x-axis and y-axis were 0.482 mm and 0.552 mm, respectively. The maximum warpage value of bottom part specimen in x-axis and y-axis were 0.185 mm and 0.182 mm, respectively. Compression test found that VC specimen started to fail when compression height reached 3.94 mm. For mold relief stress test, the deviation of bottom casing was within 0.351 mm to 0.492 mm for x- direction and 0.426 mm to 0.683 mm for y-direction. Next, top casing showed the deviation values of 0.391 mm to 0.423 mm and 0.582 mm to 0.690 mm for x-direction and y-direction, respectively. Results from drop test and mold relief stress test were successfully used to validate and define the impact tolerance of the mating parts. In conclusion, the study has successfully showed that, RVC process can be an alternative way in producing beta prototypes. zainurin UTM 162 p. Thesis (Sarjana Falsafah, Bidang Penyelidikan : Kejuruteraan Mekanikal) - Universiti Teknologi Malaysia, 2020 2025-03-11T06:20:27Z 2025-03-11T06:20:27Z 2020 Master's thesis https://utmik.utm.my/handle/123456789/44432 vital:144712 valet-20211209-134527 ENG Closed Access UTM Complete Unpublished Completion application/pdf Universiti Teknologi Malaysia |
| spellingShingle | Mechanical engineering Nur Nabilah Mohammad Mustafa Raped vacuum casting performance evaluation of product with matting components for beta prototyping |
| thesis_level |
Master
|
| title | Raped vacuum casting performance evaluation of product with matting components for beta prototyping |
| title_full | Raped vacuum casting performance evaluation of product with matting components for beta prototyping |
| title_fullStr | Raped vacuum casting performance evaluation of product with matting components for beta prototyping |
| title_full_unstemmed | Raped vacuum casting performance evaluation of product with matting components for beta prototyping |
| title_short | Raped vacuum casting performance evaluation of product with matting components for beta prototyping |
| title_sort | raped vacuum casting performance evaluation of product with matting components for beta prototyping |
| topic | Mechanical engineering |
| url | https://utmik.utm.my/handle/123456789/44432 |
| work_keys_str_mv | AT nurnabilahmohammadmustafa rapedvacuumcastingperformanceevaluationofproductwithmattingcomponentsforbetaprototyping |